Million Dollar Building Terra Cotta Improvements

Los Angeles, Los Angeles County,
California, USA

The Million Dollar Building is significant to the Broadway area of Los Angeles, not only for its distinctive architectural decoration, but also for its connection to L.A. history. The upper floors were originally theoffices of the Metropolitan Water District and William Mulholland. The ground floor holds the Million Dollar Theater, the first theater built in L.A. by Sid Graumann, known later for building Graumann's Chinese Theater in Hollywood.

Unfortunately, time and design flaws had conspired to make much of the upper portions of the building hazardous to pedestrians below. Many large and potentially lethal pieces of terra cotta were removed by hand, indicating how close the facade was to falling apart at the next earthquake. Infiltration of moisture through cracks and joints caused much of the internal steel reinforcement to rust and expand, forcing apart many of the terra cotta units. Close inspection revealed that these units had been undergoing this decay process for a substantial period prior to our intervention. Evidence of stop gap maintenance was everywhere, in the form of old caulk and mortar placed in the cracks in an attempt to retard the intrusion of moistue. Seismic activityalso accounted for the shifting of various large terra cotta units, further allowing moisture to intrue to the interor steel structure.

Since the budget did not allow for the expense of completely taking the damaged terra cotta units apart, we opted to 'stitch' the damaged terra cotta pieces together using over 2,000 steel pins. Crack repair involved preparing the cracks by routing out the void to a depth necessary to provide adequate purchase for the repair mortar. The repaired cracks and anchor pin holes were filled with mortar and then coated with epoxy paint formulated to match the original cleaned glaze in color and appearance.

Decorative features on the exterior facade are rich with baroque excess, as in these columns and frieze at the parapet area. Infiltration of moisture through cracks and joints caused much of the structural steel reinforcement to rust and expand, forcing apart many of the terra cotta units. Seismic activity also accounted for the shifting of various large terra cotta units.

Wonderful details are present throughout the Broadway and 3rd Street elevations of the building.

Unfortunately, time and design flaws had conspired to make much of the upper portions of the building hazardous to pedestrians below. Infiltration of moisture through cracks and joints caused much of the internal steel reinforcement to rust and expand, forcing apart many of the terra cotta units, as in this detached column.

Closer inspection revealed that these units had been undergoing this decay process for a substantial period prior to our intervention.

Evidence of stop gap maintenance was everywhere, in the form of old caulk and mortar placed in the cracks in an attempt to retard the intrusion of moisture.

Previous seismic activity also accounted for the shifting of various large terra cotta units, further allowing moisture to intrude to the interior steel structure.

Seeds deposited in pigeon guano had a good start at growing in the grout lines.

In large areas where the grout lines had been caulked with old oil-based material instead of properly repointed, the caulk had simply given up the ghost.

Our restoration program was initially challenged by the fact that the sidewalk below would not support the weight of the scaffolding required to gain access to all parts of the upper parapet. Our scaffolding contractor cleverly installed fixed scaffolding supported by firm attachment to the roof, with little or no support scaffolding running from the ground.

This allowed for scaffolding on 75% of the project to be unsupported from the ground level.

Many large and potentially lethal pieces of terra cotta were removed by hand, indicating how close the facade was to falling apart at the next earthquake. Additionally, the interior iron was easily pried apart where long term exposure to moisture had caused iron jacking.

Many pieces weighing up to 20 pounds were easily removed by hand with a screwdriver.

Since the budget did not allow for the expense of completely taking the damaged terra cotta units apart, we opted for the next best intervention plan. Our stabilization program called for the installation of stainless steel spiral pins to "stitch" the damaged terra cotta pieces together. This required the drilling of a 1/4" hole to receive the new pin.

The pin is then vibrated into the previously drilled hole and relies upon a friction fit to firmly clamp the two pieces together. Over 2,000 pins were installed in the damaged terra cotta in this fashion.

Crack repair involved preparing the cracks by routing out the void to a depth necessary to provide adequate purchase for the repair mortar.

The repaired cracks and anchor pin holes were filled with mortar and then coated with epoxy paint formulated to match the original cleaned glaze in color and appearance.

Here a repaired column body and base has been patched and is waiting for the final coating.

The column is now completed and good for at least another 40-50 years.

Several areas had material loss due to the rusting of steel railings and had to be rebuilt with the special repair mortar and then coated.

Some of the largest terra cotta units to give us concern were at the tower where some old light fixture conduit had provided an easy path for rainwater to get inside and start the decay process.

The old cement caps had failed years before and there were several pieces ready to come down.

Here we have installed stainless steel saddle anchors set in epoxy adhesive to help hold together the pieces trying to slip off the building.

The columns are now thoroughly waterproofed and stabilized.

The Million Dollar Building is a great symbol of the early days in Los Angeles and better able now to withstand the forces of weathering that affect all structures, old or new.